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Industrial Furnaces, Sixth Edition. W. Trinks, M. H. Mawhinney, R. A. Shannon, R. J. Reed and J. R. Garvey Copyright © 2004 John Wiley & Sons, Inc.
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CHRONOLOGY of Trinks and Mawhinney books on furnaces INDUSTRIAL FURNACES Volume I First Edition, by W. Trinks, 1923 6 chapters, 319 pages, 255 figures Volume I Second Edition, by W. Trinks, 1926
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Volume I Third Edition, by W. Trinks, 1934 6 chapters, 456 pages, 359 figures, 22 tables
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Volume I Fourth Edition, by W. Trinks, 1951 6 chapters, 526 pages, 414 figures, 26 tables Volume I Fifth Edition, by W. Trinks and M. H. Mawhinney, 1961 8 chapters, 486 pages, 361 figures, 23 tables Volume I Sixth Edition, by W. Trinks, M. H. Mawhinney, R. A. Shannon, R. J. Reed, and J. R. V. Garvey, 2000 9 chapters, 490 pages, 199 figures,* 40 tables Volume II First Edition, by W. Trinks, 1925 Volume II Second Edition, by W. Trinks, 1942 6 chapters, 351 pages, 337 figures, 12 tables Volume II Third Edition, by W. Trinks, 1955 7 chapters, 358 pages, 303 figures, 4 tables Volume II Fourth Edition, by W. Trinks and M. H. Mawhinney, 1967** 9 chapters, 358 pages, 273 figures, 13 tables PRACTICAL INDUSTRIAL FURNACE DESIGN, by M. H. Mawhinney, 1928 9 chapters, 318 pages, 104 figures, 28 tables
*
This 6th Edition also includes 3 equations, 20 examples, 54 review questions, 4 problems, and 5 suggested projects. The 199 figures consist of 43 graphs, 140 drawings and diagrams, and 16 photographs.
** No further editions of Volume II of INDUSTRIAL FURNACES are planned because similar, but up-todate, material is covered in this 6th Edition of INDUSTRIAL FURNACES and in Volumes I and II of the North American COMBUSTION HANDBOOK.
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INDUSTRIAL FURNACES, SIXTH EDITION [-3], (3)
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JOHN WILEY & SONS, INC.
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This book is printed on acid-free paper. Copyright © 2004 by John Wiley & Sons, Inc. All rights reserved. Published by John Wiley & Sons, Inc., Hoboken, New Jersey Published simultaneously in Canada No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, scanning, or otherwise, except as permitted under Section 107 or 108 of the 1976 United States Copyright Act, without either the prior written permission of the Publisher, or authorization through payment of the appropriate per-copy fee to the Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923, (978) 750-8400, fax (978) 750-4470, or on the Web at www.copyright.com. Requests to the Publisher for permission should be addressed to the Permissions Department, John Wiley & Sons, Inc., 111 River Street, Hoboken, NJ 07030, (201) 748-6011, fax (201) 748-6008, email:
[email protected]. Limit of Liability/Disclaimer of Warranty: While the publisher and the author have used their best efforts in preparing this book, they make no representations or warranties with respect to the accuracy or completeness of the contents of this book and specifically disclaim any implied warranties of merchantability or fitness for a particular purpose. No warranty may be created or extended by sales representatives or written sales materials. The advice and strategies contained herein may not be suitable for your situation. You should consult with a professional where appropriate. Neither the publisher nor the author shall be liable for any loss of profit or any other commercial damages, including but not limited to special, incidental, consequential, or other damages. For general information about our other products and services, please contact our Customer Care Department within the United States at (800) 762-2974, outside the United States at (317) 572-3993 or fax (317) 572-4002. Wiley also publishes its books in a variety of electronic formats. Some content that appears in print may not be available in electronic books. For more information about Wiley products, visit our Web site at www.wiley.com. Library of Congress Cataloging-in-Publication Data: Industrial furnaces / Willibald Trinks . . . [et al.]. — 6th ed. p. cm. Previous ed. cataloged under: Trinks, W. (Willibald), b. 1874. Includes bibliographical references and index. ISBN 0-471-38706-1 (Cloth) 1. Furnaces—Design and construction. 2. Furnaces—Industrial applications. (Willibald), b. 1874. II. Trinks, W. (Willibald), b. 1874. Industrial furnaces. TH7140 .I48 2003 621.402'5—dc21
I. Trinks, W.
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This 6th Edition is dedicated to our wives: Emily Jane Shannon and Catherine Riehl Reed whom we thank for beloved encouragement and for time away to work on this 6th Edition. ROBERT A. SHANNON Avon Lake, Ohio
RICHARD J. REED Willoughby, Ohio
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[Last Pag [-6], (6)
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CONTENTS Excerpts from the Preface to the 5th Edition
xv
Preface
xvii
Brief Biographies of the Author
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No-Liability Statement
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INDUSTRIAL HEATING PROCESSES
1
1.1
Industrial Process Heating Furnaces / 1
1.2
Classifications of Furnaces / 7 1.2.1 Furnace Classification by Heat Source / 7 1.2.2 Furnace Classification by Batch or Continuous, and by Method of Handling Material into, Through, and out of the Furnace / 7 1.2.3 Furnace Classification by Fuel / 16 1.2.4 Furnace Classification by Recirculation / 18 1.2.5 Furnace Classification by Direct-Fired or Indirect-Fired / 18 1.2.6 Classification by Furnace Use / 20 1.2.7 Classification by Type of Heat Recovery / 20 1.2.8 Other Furnace Type Classifications / 21
1.3
Elements of Furnace Construction / 22
1.4
Review Questions and Projects / 23
HEAT TRANSFER IN INDUSTRIAL FURNACES 2.1
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Heat Required for Load and Furnace / 25 2.1.1 Heat Required for Heating and Melting Metals / 25 vii
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CONTENTS
2.1.2 2.2
Flow of Heat Within the Charged Load / 28 2.2.1 Thermal Conductivity and Diffusion / 28 2.2.2 Lag Time / 30
2.3
Heat Transfer to the Charged Load Surface / 31 2.3.1 Conduction Heat Transfer / 33 2.3.2 Convection Heat Transfer / 35 2.3.3 Radiation Between Solids / 37 2.3.4 Radiation from Clear Flames and Gases / 42 2.3.5 Radiation from Luminous Flames / 46
2.4
Determining Furnace Gas Exit Temperature / 53 2.4.1 Enhanced Heating / 55 2.4.2 Pier Design / 56
2.5
2.6
3
Heat Required for Fusion (Vitrification) and Chemical Reaction / 26
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Thermal Interaction in Furnaces / 57 2.5.1 Interacting Heat Transfer Modes / 57 2.5.2 Evaluating Hydrogen Atmospheres for Better Heat Transfer / 60
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Temperature Uniformity / 63 2.6.1 Effective Area for Heat Transfer / 63 2.6.2 Gas Radiation Intensity / 64 2.6.3 Solid Radiation Intensity / 64 2.6.4 Movement of Gaseous Products of Combustion / 64 2.6.5 Temperature Difference / 65
2.7
Turndown / 67
2.8
Review Questions and Project / 67
HEATING CAPACITY OF BATCH FURNACES 3.1
Definition of Heating Capacity / 71
3.2
Effect of Rate of Heat Liberation / 71
3.3
Effect of Rate of Heat Absorption by the Load / 77 3.3.1 Major Factors Affecting Furnace Capacity / 77
3.4
Effect of Load Arrangement / 79 3.4.1 Avoid Deep Layers / 83
3.5
Effect of Load Thickness / 84
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CONTENTS
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3.6
Vertical Heating / 85
3.7
Batch Indirect-Fired Furnaces / 86
3.8
Batch Furnace Heating Capacity Practice / 91 3.8.1 Batch Ovens and Low-Temperature Batch Furnaces / 92 3.8.2 Drying and Preheating Molten Metal Containers / 96 3.8.3 Low Temperature Melting Processes / 98 3.8.4 Stack Annealing Furnaces / 99 3.8.5 Midrange Heat Treat Furnaces / 101 3.8.6 Copper and Its Alloys / 102 3.8.7 High-Temperature Batch Furnaces, 1990 F to 2500 F / 103 3.8.8 Batch Furnaces with Liquid Baths / 108
3.9
Controlled Cooling in or After Batch Furnaces / 113
3.10 4
Review Questions and Project / 114
HEATING CAPACITY OF CONTINUOUS FURNACES
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4.1
Continuous Furnaces Compared to Batch Furnaces / 117 4.1.1 Prescriptions for Operating Flexibility / 118
4.2
Continuous Dryers, Ovens, and Furnaces for 1260 C), “high temperatures” = 1900– 2300 F (1038–1260 C), “midrange temperatures” = 1100–1900 F (593–1038 C), and “low temperatures” = < 1100 F (1260 C), “high temperature” = 1900–2300 F (1038–1260 C), “midrange temperature” = 1100–1900 F (593–1038 C), and “low temperature” =
